U.S. patent number 10,442,179 [Application Number 15/237,149] was granted by the patent office on 2019-10-15 for 3d printer with spool and material container.
This patent grant is currently assigned to STRATASYS, INC.. The grantee listed for this patent is Stratasys, Inc.. Invention is credited to Shawn Michael Koop, Jordan Paul Nadeau, Samuel Ogrodnik, Peter D. Schuller.
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United States Patent |
10,442,179 |
Koop , et al. |
October 15, 2019 |
3D printer with spool and material container
Abstract
A 3D printer has a gantry configured to move in a plane
substantially parallel to a build plane, and a platen configured to
support a part being built. The platen is configured to move in a
direction substantially normal to the build plane. A head carriage
is carried by the gantry, and a print head is carried by and
retained in the head carriage. A material container has a material
container body and a material container cover configured to allow
loading of a spool containing a supply of a consumable filament for
printing with the 3D printer, the spool mounted on an axle
containing a spool chip and electrical contacts. The material
container body includes a first and second axle channels configured
to accept first and second ends of the axle. The first axle channel
has a number of electrical contacts and is tapered to orient the
axle to align the axle contacts with the first axle channel
contacts. A material well has first and second well edge landings
at a first radius from the central longitudinal axis, the well edge
landings extending toward each other from inner edges of the
material well inwardly toward a center of the material well. An
extension well extends laterally from the first and second well
edge landings to a second radius larger than the first radius.
Inventors: |
Koop; Shawn Michael (Blaine,
MN), Schuller; Peter D. (Elko, MN), Nadeau; Jordan
Paul (St. Louis Park, MN), Ogrodnik; Samuel (Minnetonka,
MN) |
Applicant: |
Name |
City |
State |
Country |
Type |
Stratasys, Inc. |
Eden Prairie |
MN |
US |
|
|
Assignee: |
STRATASYS, INC. (Eden Prairie,
MN)
|
Family
ID: |
61160903 |
Appl.
No.: |
15/237,149 |
Filed: |
August 15, 2016 |
Prior Publication Data
|
|
|
|
Document
Identifier |
Publication Date |
|
US 20180043629 A1 |
Feb 15, 2018 |
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B29C
64/118 (20170801); B29C 64/255 (20170801); B33Y
30/00 (20141201); B33Y 50/02 (20141201) |
Current International
Class: |
B29C
64/118 (20170101); B33Y 30/00 (20150101); B29C
64/255 (20170101); B33Y 50/02 (20150101) |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: Minskey; Jacob T
Assistant Examiner: Darnell; Baileigh Kate
Attorney, Agent or Firm: Westman, Champlin & Koehler,
P.A.
Claims
The invention claimed is:
1. A 3D printer, comprising: a gantry configured to move in a plane
substantially parallel to a build plane; a platen configured to
support a part being built in a layer by layer process, wherein the
platen is configured to move in a direction substantially normal to
the build plane; a head carriage carried by the gantry; a print
head carried by and retained in the head carriage; and a material
container, comprising: a material container body and a material
container cover, the material container body and material container
cover configured to allow loading of a spool containing a supply of
a consumable filament for printing with the 3D printer, the spool
mounted on an axle containing a spool chip and a first plurality of
electrical contacts, the material container body comprising: a
first axle channel configured to accept a first end of the axle,
and a second axle channel configured to accept a second end of the
axle, the first axle channel having a different configuration than
the second axle channel, the first axle channel having a second
plurality of electrical contacts and being tapered to orient the
axle to align the first plurality of electrical contacts with the
second plurality of electrical contacts.
2. The 3D printer of claim 1, wherein a bottom of the first axle
channel and a bottom of the second axle channel are each configured
to accept an axle end therein and align the axle on a central
longitudinal axis of the material container.
3. The 3D printer of claim 2, wherein the material container body
further comprises a material well, the material well comprising:
first and second well edge landings at a first radius from the
central longitudinal axis, the first well edge landing extending
from a first inner edge of the material well inwardly toward a
center of the material well, the second well edge landing extending
from a second, opposite, inner edge of the material well inwardly
toward the center of the material well; and an extension well
extending laterally from the first and second well edge landings to
a second radius larger than the first radius.
4. The 3D printer of claim 3, wherein the extension well has a
width configured to be substantially the same as a width of a
filament winding area of the inserted spool.
5. The 3D printer of claim 3, wherein the first radius is
substantially equal to a radius of an inserted spool.
6. The 3D printer of claim 1, wherein the material container cover
further comprises: first and second of curved inner guide
components each extending from a top inner edge of the material
container cover; and a plurality of ribs extending laterally from
each side of the material container cover and configured to align
the material container cover to the material container body to
align the first and second curved inner guides with the first and
second well edge landings.
7. The 3D printer of claim 1, wherein the first and second
plurality of electrical contacts each comprise: a first ground
contact; and two electrically connected power contacts.
8. The 3D printer of claim 7, wherein the first ground contact is
positioned between the two electrically connected power contacts in
the first axle channel.
9. A 3D printer, comprising: a gantry configured to move in a plane
substantially parallel to a build plane; a platen configured to
support a part being built in a layer by layer process, wherein the
platen is configured to move in a direction substantially normal to
the build plane; a head carriage carried by the gantry; a print
head carried by and retained in the head carriage; and a material
container, comprising: a material container body and a material
container cover, the material container body and material container
cover configured to allow loading of a spool containing a supply of
a consumable filament for printing with the 3D printer, the spool
mounted on an axle having a longitudinal axis, wherein the spool is
configured to rotate about the axle and the longitudinal axis, the
material container body comprising: a first axle channel configured
to accept a first end of the axle, and a second axle channel
configured to accept a second end of the axle, the first axle
channel having a different configuration than the second axle
channel, the first axle channel having at least one surface that is
configured to engage the first end of the axle and prevent rotation
of the axle about the longitudinal axis.
10. The 3D printer of claim 9, wherein the first end of the axle
comprises a first plurality of electrical contacts and wherein the
material container body comprises a second having a second
plurality of electrical contacts within the first axle channel,
wherein the first and second plurality of electrical contacts are
aligned to compete a circuit.
11. The 3D printed of claim 9, wherein the first axle channel has a
top entrance and bottom axle engaging end, wherein a width of the
first axle channel decreases from the top entrance to the axle
engaging end to align the first and second plurality of electrical
contacts to complete the circuit.
12. The 3D printer of claim 9, wherein a bottom surface of the
first axle channel and a second bottom of the second axle channel
are each configured to accept the first and second ends of the
axle, respectively, and align the longitudinal axis of the axle
with a central axis of the material container.
13. The 3D printer of claim 9, wherein the material container body
further comprises a material well, the material well comprising:
first and second well edge landings at a first radius from the
central longitudinal axis, the first well edge landing extending
from a first inner edge of the material well inwardly toward a
center of the material well, the second well edge landing extending
from a second, opposite, inner edge of the material well inwardly
toward the center of the material well; and an extension well
extending laterally from the first and second well edge landings to
a second radius larger than the first radius.
14. The 3D printer of claim 13, wherein the extension well has a
width configured to be substantially the same as a width of a
filament winding area of the inserted spool.
15. A 3D printer, comprising: a gantry configured to move in a
plane substantially parallel to a build plane; a platen configured
to support a part being built in a layer by layer process, wherein
the platen is configured to move in a direction substantially
normal to the build plane; a head carriage carried by the gantry; a
print head carried by and retained in the head carriage; and a
material container, comprising: a material container body and a
material container cover, the material container body and material
container cover configured to allow loading of a spool containing a
supply of a consumable filament for printing with the 3D printer,
the spool mounted on an axle having a longitudinal axis, wherein
the spool is configured to rotate about the axle and the
longitudinal axis, the material container body comprising: a first
axle channel configured to accept a first end of the axle, and a
second axle channel configured to accept a second end of the axle,
the first axle channel having a different configuration than the
second axle channel, the second axle channel having a width that is
less than a minimum width of the first end of the axle and the
first axle channel such that improper insertion of the spool within
the material container body is prevented.
16. The 3D printer of claim 15 wherein the first axle channel
comprises at least one surface that is configured to engage the
first end of the axle and prevent rotation of the axle about a
longitudinal axis such that the spool rotates about the axle.
17. The 3D printer of claim 15, wherein the first end of the axle
comprises a first plurality of electrical contacts and wherein the
a material container body comprises a second having a second
plurality of electrical contacts within the first axle channel,
wherein the first and second plurality of electrical contacts are
aligned to compete a circuit.
18. The 3D printer of claim 15, wherein the first end of the axle
comprises a first plurality of electrical contacts and wherein the
material container body comprises a second having a second
plurality of electrical contacts within the first axle channel,
wherein the first and second plurality of electrical contacts are
aligned to compete a circuit.
19. The 3D printed of claim 18, wherein the first axle channel has
a top entrance and bottom axle engaging end, wherein a width of the
first axle channel decreases from the top entrance to the axle
engaging end to align the first and second plurality of electrical
contacts to complete the circuit.
Description
BACKGROUND
The present disclosure relates to 3D printers for printing
three-dimensional (3D) parts. In particular, the present disclosure
relates to spools of material and material containers for additive
manufacturing devices for printing 3D parts and support structures
in a layered manner using fused deposition modeling techniques.
Additive manufacturing, also called 3D printing, is generally a
process in which a three-dimensional (3D) object is built by adding
material to form a 3D part rather than subtracting material as in
traditional machining. One basic operation of an additive
manufacturing system consists of slicing a three-dimensional
computer model into thin cross sections, translating the result
into two-dimensional position data, and feeding the data to control
equipment which manufacture a three-dimensional structure in an
additive build style. Additive manufacturing entails many different
approaches to the method of fabrication, including fused deposition
modeling, ink jetting, selective laser sintering, powder/binder
jetting, electron-beam melting, electrophotographic imaging, and
stereolithographic processes. Using one or more additive
manufacturing techniques, a three-dimensional solid object of
virtually any shape can be printed from a digital model of the
object by an additive manufacturing system, commonly referred to as
3D printer.
In a fused deposition modeling additive manufacturing system, a
printed part may be printed from a digital representation of the
printed part in an additive build style by extruding a flowable
part material along toolpaths. The part material is extruded
through an extrusion tip carried by a print head of the system, and
is deposited as a sequence of roads onto a substrate. The extruded
part material fuses to previously deposited part material, and
solidifies upon a drop in temperature. In a typical system where
the material is deposited in planar layers, the position of the
print head relative to the substrate is incremented along an axis
(perpendicular to the build plane) after each layer is formed, and
the process is then repeated to form a printed part resembling the
digital representation.
In fabricating printed parts by depositing layers of a part
material, supporting layers or structures are typically built
underneath overhanging portions or in cavities of printed parts
under construction, which are not supported by the part material
itself. A support structure may be built utilizing the same
deposition techniques by which the part material is deposited. A
host computer generates additional geometry acting as a support
structure for the overhanging or free-space segments of the printed
part being formed. Support material is then deposited from a second
nozzle pursuant to the generated geometry during the printing
process. The support material adheres to the part material during
fabrication, and is removable from the completed printed part when
the printing process is complete.
SUMMARY
An aspect of the present disclosure is directed to a 3D printer
having a gantry configured to move in a plane substantially
parallel to a build plane, and a platen configured to support a
part being built in a layer by layer process. The platen is
configured to move in a direction substantially normal to the build
plane. A head carriage is carried by the gantry, and a print head
is carried by and retained in the head carriage. A material
container includes a material container body and a material
container cover. The material container body and material container
cover are configured to allow loading of a spool containing a
supply of a consumable filament for printing with the 3D printer,
the spool mounted on an axle containing a spool chip and a
plurality of electrical contacts. The material container body
includes a first axle channel configured to accept a first end of
the axle, and a second axle channel configured to accept a second
end of the axle. The first axle channel has a different
configuration than the second axle channel. The first axle channel
has a plurality of electrical contacts and is tapered to orient the
axle to align the axle the first axle channel contacts.
Another aspect of the present disclosure is directed toward a
consumable assembly for a 3D printer. The assembly includes a spool
and an axle. The spool has spaced apart spool walls, a hub, a
filament winding area defined by the spool walls and the hub, and a
central passage extending longitudinally through the hub. The axle
is configured to be retained within the central passage, the axle
insertable into the central passage in only one direction.
Another aspect of the present disclosure is directed toward a
material container for a 3D printer. The material container
includes a material container body and a material container cover.
The material container body and material container cover are
configured to allow loading of a spool containing a supply of a
consumable filament for printing with the 3D printer, the spool
mounted on an axle containing a spool chip and a plurality of
electrical contacts. The material container body includes a first
axle channel configured to accept a first end of the axle, and a
second axle channel configured to accept a second end of the axle.
The first axle channel has a plurality of electrical contacts and
is tapered to orient the axle to align the axle contacts with the
first axle channel contacts. A bottom of the first axle channel and
a bottom of the second axle channel are configured to accept an
axle therein and align the axle on a central longitudinal axis of
the material container. The material container body further
comprises a material well. The material well includes first and
second well edge landings at a first radius from the central
longitudinal axis. The first well edge landing extends from a first
inner edge of the material well inwardly toward a center of the
material well. The second well edge landing extends from a second,
opposite, inner edge of the material well inwardly toward the
center of the material well. An extension well extends laterally
from the first and second well edge landings to a second radius
larger than the first radius.
DEFINITIONS
Unless otherwise specified, the following terms as used herein have
the meanings provided below:
The terms "preferred", "preferably", "example" and "exemplary"
refer to embodiments of the invention that may afford certain
benefits, under certain circumstances. However, other embodiments
may also be preferred or exemplary, under the same or other
circumstances. Furthermore, the recitation of one or more preferred
or exemplary embodiments does not imply that other embodiments are
not useful, and is not intended to exclude other embodiments from
the scope of the present disclosure.
Directional orientations such as "above", "below", "top", "bottom",
and the like are made with reference to a layer-printing direction
of a 3D part. In the embodiments shown below, the layer-printing
direction is the upward direction along the vertical z-axis. In
these embodiments, the terms "above", "below", "top", "bottom", and
the like are based on the vertical z-axis. However, in embodiments
in which the layers of 3D parts are printed along a different axis,
such as along a horizontal x-axis or y-axis, the terms "above",
"below", "top", "bottom", and the like are relative to the given
axis.
The term "providing", such as for "providing a material", when
recited in the claims, is not intended to require any particular
delivery or receipt of the provided item. Rather, the term
"providing" is merely used to recite items that will be referred to
in subsequent elements of the claim(s), for purposes of clarity and
ease of readability.
Unless otherwise specified, temperatures referred to herein are
based on atmospheric pressure (i.e. one atmosphere).
The terms "about" and "substantially" are used herein with respect
to measurable values and ranges due to expected variations known to
those skilled in the art (e.g., limitations and variabilities in
measurements).
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of a 3D printer configured to print 3D parts
and support structures with the use of one or more print heads of
the present disclosure.
FIG. 2 is a perspective view of a spool and axle assembly according
to an embodiment of the present disclosure.
FIG. 3 is a perspective view of an opposite side of the spool and
axle assembly of FIG. 2.
FIG. 4 is a section view of the spool and axle assembly of FIG. 2
along section line 4-4.
FIG. 5 is a perspective view of an axle according to an embodiment
of the present disclosure.
FIG. 6 is a side elevation view of the axle of FIG. 5.
FIG. 7 is an end elevation view of the axle of FIG. 5.
FIG. 8 is a perspective view of a material container body according
to an embodiment of the present disclosure.
FIG. 9 is a perspective view of the material container body of FIG.
8 from its opposite side.
FIG. 10 is section view of the material container body of FIG. 8
taken along section line 10-10.
FIG. 11 is a top view of the material container body of FIG. 8.
FIG. 12 is a section view of the material container body of FIG. 11
taken along section line 12-12, and showing a material container
cover.
FIG. 13 is an underside view of a material container cover for a
material container according to an embodiment of the present
disclosure.
FIG. 14 is a perspective view of the material container cover of
FIG. 13.
FIG. 15 is a partial cutaway view showing a spool and axle in a
material container body according to an embodiment of the present
disclosure.
FIG. 16 is a perspective section view of a spool, axle, and
material container body according to an embodiment of the present
disclosure.
FIG. 17 is a section view of a material container, spool, and axle
according to an embodiment of the present disclosure.
DETAILED DESCRIPTION
The present disclosure is directed to consumable assemblies
containing a supply of consumable filament for use in material
containers of an additive manufacturing device, commonly referred
to as a 3D printer. The consumable assemblies feed filament from a
spool in the material container to the 3D printer, and may include
a spool chip for storing and updating data, specifications and
other information about the filament wound on the spool. The data
on a spool chip typically comprises nonexecuting code that includes
information such as the amount of material in the cartridge, the
type of material, and the batch number. The printer may interrogate
the spool chip to verify the material, keep track of the length or
volume of material withdrawn from the cartridge during printing,
and write the new count back to the spool chip to update its
information. The present disclosure is also directed to material
containers for retention of spools and for feeding filament from
the consumable assemblies.
Material spools have previously been provided for 3D printers in a
variety of ways. For example, the spool may be provided with a
spool chip affixed to the spool or spool hub, as is disclosed for
example in U.S. Pat. No. 6,022,207, and shipped in a moisture-proof
bag. The spool may be contained within a consumable assembly, and
having a spool chip mounted to the consumable assembly, such as
disclosed in U.S. Pat. No. 7,063,285. The spool may be assembled in
a consumable assembly and further packaged with an associated print
head, such as disclosed in U.S. Pat. No. 9,073,263.
Where a consumable assembly is used, it generally is provided by a
supplier, installed by a user, and retained on the 3D printer
during operation. The packaging in which the consumable assembly is
shipped is either disposed upon installation to the 3D printer, is
returned to the supplier for reuse, or is recycled or otherwise
disposed of. Such shipping back and forth, or disposal of packaging
material, is not cost effective.
Some consumable assemblies are provided as a spool of filament
along with a separate device containing the spool chip, and through
which the filament is initially fed, as is disclosed in U.S. Pat.
No. 7,938,351. Following feeding of the filament through the
component, the spool and component are arranged into a material
container, and the material container is loaded into the 3D printer
for operation. As the components containing the spool chip may all
look alike, and as different filament materials may have different
use specifications that are encoded on the spool chip, loss of an
unattached chip component or accidental mismatching of a chip
component with a material on a spool can cause part errors and/or
inoperability of the consumable assembly.
Further, once a filament spool material is exposed to ambient
conditions, the filament begins to take on moisture. As more
moisture is absorbed, filament and part quality degrade. Therefore,
many materials are packaged in water resistant packaging. Many of
the previously used methods of providing the material spools for
operation may be installed into a machine incorrectly, especially
in light of the additional packaging to prevent moisture
absorption. Incorrect installation can result in misfeeding of the
filament, jamming or tangling of the filament, or the like.
Further, if the filament material or container is installed
incorrectly into the 3D printer, additional time may be used to
correct the issue, leading to additional moisture absorption by the
filament material. Still further, once a misfeed occurs, the
typical solution for the issue is to return the material spool to
the supplier, all of which uses additional time and money, both of
which lead to inefficiencies in the additive manufacturing
process.
Still further, spools that are situated in a container or other
assembly typically have spool walls that have a gap between the
exterior radial edge of the spool and the container. Rotation of
the spool with respect to the container can lead to filament being
wedged into the gap, snagging the filament and stopping the ability
of the 3D printer to continue operation. Further, any drag placed
on the filament due to snagging or catching in gaps, such as those
described, increases the pull force on the filament, which is
problematic especially for 3D printers that pull the filament into
a material liquefier.
Spools and material containers of the present disclosure are
configured so that the spool can only be loaded properly into the
material container. The spools and material containers of the
present disclosure may be used with any suitable extrusion-based 3D
printer, although some retrofitting may be required for existing
systems. A newly manufactured 3D printer may be provided with the
material containers, or an existing 3D printer that feeds filament
may be retrofitted with the material containers for use of the
consumable assemblies of the present disclosure.
The present disclosure may be used with any suitable
extrusion-based 3D printer. For example, FIG. 1 illustrates a 3D
printer 10 that has a substantially horizontal print plane where
the part being printed in indexed in a substantially vertical
direction as the part is printed in a layer by layer manner using
two print heads 18. The illustrated 3D printer 10 uses two
consumable assemblies 12, where each consumable assembly 12 is an
easily loadable, removable, and replaceable container device that
retains a supply of a consumable filament for printing with 3D
printer 10. Typically, one of the consumable assemblies 12 contains
a part material filament, and the other consumable assembly 12
contains a support material filament, each supplying material to
one of the print heads 18. However, both consumable assemblies 12
may be identical in structure. Each consumable assembly 12 may
retain the consumable filament on a wound spool, a spool-less coil,
or other supply arrangement, such as discussed in Swanson et al.,
U.S. Pat. No. 7,374,712; Taatjes at al., U.S. Pat. No. 7,938,356;
Mannella et al., U.S. Pat. Nos. 8,985,497 and 9,073,263; and
Batchelder et al., U.S. Publication No. 2014/0158802.
Each print head 18 is an easily loadable, removable and replaceable
device comprising a housing that retains a liquefier assembly 20
having a nozzle tip 14. Each print head 18 is configured to receive
a consumable material, melt the material in liquefier assembly 20
to product a molten material, and deposit the molten material from
a nozzle tip 14 of liquefier assembly 20. Examples of suitable
liquefier assemblies for print heads 18 include those disclosed in
Swanson et al., U.S. Pat. No. 6,004,124; LaBossiere, et al., U.S.
Pat. No. 7,604,470; Leavitt, U.S. Pat. No. 7,625,200; and
Batchelder et al., U.S. Pat. No. 8,439,665. Other suitable
liquefier assemblies include those disclosed in U.S. Patent
Publications Nos. 2015/0096717 and 2015/0097053; and in PCT
publication No. WO2016014543A.
Guide tubes 16 interconnect consumable assemblies 12 and print
heads 18, where a drive mechanism of print head 18 (or of 3D
printer 10) draws successive segments of the consumable filament
from consumable assembly 12, through guide tube 16, to liquefier
assembly 20 of print head 18. In this embodiment, guide tube 16 may
be a component of 3D printer 10, rather than a sub-component of
consumable assemblies 12. In other embodiments, guide tube 16 is a
sub-component of consumable assembly 12, and may be interchanged to
and from 3D printer 10 with each consumable assembly 12. During a
build operation, the successive segments of consumable filament
that are driven into print head 18 are heated and melt in liquefier
assembly 20. The melted material is extruded through nozzle tip 14
in a layerwise pattern to produce printed parts.
3D printer 10 prints 3D parts or models and corresponding support
structures (e.g., 3D part 22 and support structure 24) from the
part and support material filaments, respectively, of consumable
assemblies 12, using a layer-based, additive manufacturing
technique. Suitable 3D printers for 3D printer 10 include
extrusion-based systems developed by Stratasys, Inc., Eden Prairie,
Minn. under the trademark "FDM".
As shown, 3D printer 10 includes system casing 26, chamber 28,
platen 30, platen gantry 32, head carriage 34, and head gantry 36.
System casing 26 is a structural component of 3D printer 10 and may
include multiple structural sub-components such as support frames,
housing walls, and the like. In some embodiments, system casing 26
may include container bays configured to receive consumable
assemblies 12. In alternative embodiments, the container bays may
be omitted to reduce the overall footprint of 3D printer 10. In
these embodiments, consumable assemblies 12 may stand proximate to
system casing 26, while providing sufficient ranges of movement for
guide tubes 16 and print heads 18 that are shown schematically in
FIG. 1.
Chamber 28 is an enclosed environment that contains platen 30 for
printing 3D part 22 and support structure 24. Chamber 28 may be
heated (e.g., with circulating heated air) to reduce the rate at
which the part and support materials solidify after being extruded
and deposited (e.g., to reduce distortions and curling). In
alternative embodiments, chamber 28 may be omitted and/or replaced
with different types of build environments. For example, 3D part 22
and support structure 24 may be built in a build environment that
is open to ambient conditions or may be enclosed with alternative
structures (e.g., flexible curtains).
Platen 30 is a platform on which 3D part 22 and support structure
24 are printed in a layer-by-layer manner, and is supported by
platen gantry 32. In some embodiments, platen 30 may engage and
support a build substrate, which may be a tray substrate as
disclosed in Dunn et al., U.S. Pat. No. 7,127,309, fabricated from
plastic, corrugated cardboard, or other suitable material, and may
also include a flexible polymeric film or liner, painter's tape,
polyimide tape or other disposable fabrication for adhering
deposited material onto the platen 30 or onto the build substrate.
Platen gantry 32 is a gantry assembly configured to move platen 30
along (or substantially along) the vertical z-axis.
Head carriage 34 is a unit configured to receive and retain one or
both print heads 18, and is supported by head gantry 36. Head
carriage 34 preferably retains each print head 18 in a manner that
prevents or restricts movement of the print head 18 relative to
head carriage 34 so that nozzle tip 14 remains in the x-y build
plane, but allows nozzle tip 14 of the print head 18 to be
controllably moved out of the x-y build plane through movement of
at least a portion of the head carriage 34 relative the x-y build
plane (e.g., servoed, toggled, or otherwise switched in a pivoting
manner).
In the shown embodiment, head gantry 36 is a robotic mechanism
configured to move head carriage 34 (and the retained print heads
18) in (or substantially in) a horizontal x-y plane above platen
30. Examples of suitable gantry assemblies for head gantry 36
include those disclosed in Swanson et al., U.S. Pat. No. 6,722,872;
and Comb et al., U.S. Publication No. 2013/0078073, where head
gantry 36 may also support deformable baffles (not shown) that
define a ceiling for chamber 28. Head gantry 36 may utilize any
suitable bridge-type gantry or robotic mechanism for moving head
carriage 34 (and the retained print heads 18), such as with one or
more motors (e.g., stepper motors and encoded DC motors), capstans,
pulleys, belts, screws, robotic arms, and the like.
In an alternative embodiment, platen 30 may be configured to move
in the horizontal x-y plane within chamber 28, and head carriage 34
(and print heads 18) may be configured to move along the z-axis.
Other similar arrangements may also be used such that one or both
of platen 30 and print heads 18 are moveable relative to each
other. Platen 30 and head carriage 34 (and print heads 18) may also
be oriented along different axes. For example, platen 30 may be
oriented vertically and print heads 18 may print 3D part 22 and
support structure 24 along the x-axis or the y-axis.
System 10 also includes controller assembly 38, which may include
one or more control circuits (e.g., controller 40) and/or one or
more host computers (e.g., computer 42) configured to monitor and
operate the components of 3D printer 10. For example, one or more
of the control functions performed by controller assembly 38, such
as performing move compiler functions, can be implemented in
hardware, software, firmware, and the like, or a combination
thereof; and may include computer-based hardware, such as data
storage devices, processors, memory modules, and the like, which
may be external and/or internal to 3D printer 10.
Controller assembly 38 may communicate over communication line 44
with print heads 18, chamber 28 (e.g., with a heating unit for
chamber 28), head carriage 34, motors for platen gantry 32 and head
gantry 36, and various sensors, calibration devices, display
devices, and/or user input devices. In some embodiments, controller
assembly 38 may also communicate with one or more of platen 30,
platen gantry 32, head gantry 36, and any other suitable component
of 3D printer 10. While illustrated as a single signal line,
communication line 44 may include one or more electrical, optical,
and/or wireless signal lines, which may be external and/or internal
to 3D printer 10, allowing controller assembly 38 to communicate
with various components of 3D printer 10.
During operation, controller assembly 38 may direct platen gantry
32 to move platen 30 to a predetermined height within chamber 28.
Controller assembly 38 may then direct head gantry 36 to move head
carriage 34 (and the retained print heads 18) around in the
horizontal x-y plane above chamber 28. Controller assembly 38 may
also direct print heads 18 to selectively draw successive segments
of the consumable filaments from consumable assemblies 12 and
through guide tubes 16, respectively.
While FIG. 1 illustrates a 3D printer 10 where a build plane is in
a substantially horizontal x-y plane and the platen 30 is moved in
a z direction substantially normal to the substantially horizontal
x-y build plane, the present disclosure is not limited to a 3D
printer 10 as illustrated in FIG. 1. Rather, the present disclosure
including the coupling of the print head(s) 18 to head gantry 36
can be utilized with any 3D printer, including, but not limited to,
printing in a substantially vertical print plane and moving the
platen in a direction substantially normal to the substantially
vertical print plane.
While FIG. 1 illustrates a 3D printer 10 that utilizes a build
chamber 28 that can optionally be heated to a selected temperature,
the present disclosure is not limited to a 3D printer with a heated
chamber or a chamber. Rather, the present disclosure utilizing the
retaining mechanism and the print head(s) 18 can be utilized with
any 3D printer, including, but not limited to, 3D printers that
utilize an unheated chamber or an out of oven 3D printer. Otherwise
stated, the retaining mechanism utilized to secure the print
head(s) 18 to the head gantry 36 can be utilized on any
extrusion-based 3D printer.
Whatever 3D printer is utilized, embodiments of the disclosed
material spools, axles, and material containers may be used in a
filament based 3D printing system.
Consumable assemblies such as consumable assembly 12 as shown in
FIG. 1 comprise in one embodiment of the present disclosure,
illustrated in FIGS. 2, 3, and 4, a spool 200 and axle 250. Spool
200 comprises a pair of spool walls 202 and 204 extending radially
from a center hub 206. Center hub 206 has a passage 208
therethrough for the insertion of axle 250. Area 210 is provided
between spool walls 202 and 204, and hub 206, for the winding of
material (e.g., filament, not shown) onto spool 200. Axle 250
carries a spool chip 252 that contains information on the material
loaded on the spool 200, such as by way of example and not by way
of limitation, material type, feed rate speed and processing
temperatures, authentication of genuine material, and the like.
Axle 250 may be inserted into hub passage 208 of hub 206 in only
one direction, in this embodiment as shown through the passage 208
from spool wall 202 to spool wall 204. In order to prevent
insertion of the axle 250 into spool 200 incorrectly, the geometry
of passage 208 and axle 250 is such that an attempt to insert axle
250 into passage 208 from spool wall 204 will be unsuccessful.
FIGS. 2 and 3 are perspective views of spool 200 and axle 250
looking at spool walls 202 and 204, respectively.
FIG. 4 is a section view of spool 200 and axle 250 along section
line 4-4 of FIG. 2, where the geometry of axle 250 and spool
passage 208 are shown in greater detail. Axle 250 in one embodiment
includes a cross section with end 270 and longitudinal body 280
extending substantially perpendicular to one another. Longitudinal
body 280 includes end 260 and elements 262, 264, 266, and 268 (see
also FIGS. 5, 6, 7). End 260 is may be inserted in passage 208 at
tapered end 212 of passage 208. End 260 of axle 250 has, in one
embodiment, opposed flexible fingers 262 with extensions 263 that
form a shoulder 261. As the axle 250 is inserted into the passage
208, the fingers 262 flex toward each other due to the narrowing of
the passage 208. When the extensions 263 pass the end 214, the
fingers 262 flex away from each other, resulting in the shoulder
261 engaging the end 214, which retains the axle 250 to the spool
200.
Bearing surfaces 264 and 266 of axle 250 have diameters that are
successively larger than end 260. Spool 250 rotates about axle 250,
and the bearing surfaces 264 and 266 are configured so as to
provide support for the spool 200 via tapered passage 208. Axle
element 268 engages with end 212 of passage 208 as flexible fingers
262 engage opposite end 214 of passage 208 to removably secure axle
250 into passage 208 of spool 200.
If an attempt is made to insert axle 250 into spool 200 passage 208
from spool wall 204, the diameter of bearing surface 264 prevents
the insertion. In this manner, axle 250 may only be inserted into
passage 208 in the correct way.
Further detail of axle 250 is shown in FIGS. 5, 6, and 7. Spool
chip 252 is mounted on end 270 of axle 250. In one embodiment, end
270 is substantially perpendicular to longitudinal extension 280.
Spool chip 252 electrically couples with spool 250 using a
plurality of electrical contacts 272, 274, and 276. The electrical
contacts 272, 274, and 276 are arranged so that insertion of the
axle 250 and spool 200 into a material container body aligns the
electrical contacts 272, 274, and 276 with corresponding contacts
in the material container body.
The spool chip 252 uses two wire communication. In one embodiment,
contact 272 is configured to by a ground contact, and contacts 274
and 276 are electrically connected and are configured to carry
power and/or control signals. Therefore, inserting the axle 250 and
spool 200 into a material container body may be done from either
orientation of the end 270 to the material container body, and
electrical contact will be made with corresponding contacts in the
material container body (discussed below). It should be understood
that additional orientations of contacts, including more or fewer
contacts, could be employed without departing from the scope of the
disclosure. For example only, a concentric, target type,
configuration of contacts may be used, with a ground contact
located at a center or bulls eye of the target, and power contact
as a ring around the center of bulls eye. Such configurations will
be apparent to those of skill in the art, and are within the scope
of the disclosure.
The spool 200 and axle 250 are positionable into material container
800 as shown in FIGS. 8-14. Material container 800 is shown in
perspective view in FIG. 8. Material container 800 comprises in one
embodiment a material container body 802 and a material container
cover 804 (shown in greater detail in FIGS. 12-14). Material
container body 802 includes material well 806 into which spool 200
and axle 250 are inserted for feeding filament to the additive
manufacturing device. Material container body 802 further
comprises, in well 806, first axle channel 808 and second axle
channel 810, on opposite sides of the material container 800 in
material well 806. First axle channel 808 accepts and orients axle
250 at its end 270. First axle channel 808 has a top opening 812
sized to accommodate the end 270 of axle 250 independent of the
orientation of the axle 250 at the top opening 812. First axle
channel 808 tapers from top opening 812 to a second slot width at
814 at which slot 808 has a width equal to the smallest width of
the end 270. The bottom portion 816 of first axle channel 808 that
accommodates an axle such as axle 250 has a contact pad 818 having
center electrical contact 820 that is configured to be a ground
contact, and side electrical contacts 822 and 824. Side electrical
contacts 822 and 824 are electrically connected and are configured
in one embodiment to carry power and/or signal. The electrical
contacts 820, 822, and 824 correspond with electrical contacts 272,
274, and 276 of axle 250. Tabs 826 on either side of axle channel
808 near the bottom thereof are configured to engage tapered edges
271 of the end 270 to aid in proper alignment of the end 270 of the
axle 250 within the first axle channel 808.
FIG. 9 illustrates material container 800 in perspective view from
an opposite side of the material container 800. In FIG. 9, second
axle channel 810 is sized at its top opening 828 so that end 260 of
axle 250 is positionable within the second axle channel 810, but
end 270 of axle 250 will not fully engage second axle channel 810.
A bottom 830 of second axle channel 810 is rounded to accept the
rounded end 260 of axle 250. In this embodiment, any insertion of
the axle 250 and spool 200 into the material container 800 will
only allow proper orientation of the axle 250 and spool 200, that
is, with axle end 270 in first axle channel 808 and axle end 260 in
second axle channel 810. When a spool 200 and axle 250 are inserted
into the material container 800 in the proper orientation, a
central longitudinal axis 290 of the axle 250 intersects a center
of the contact pad 252 to ensure proper contact. The ends 270 and
260 of the axle 250 seat in the first 808 and second 810 axle
channels, and the electrical contacts 272, 274, and 276 align with
the electrical contacts 820, 822, and 824 of the first axle channel
808. The central longitudinal axis of the axle 250 aligns with the
central longitudinal axis 290 of the material container when the
axle is properly situated in the material container body 802. FIG.
10 is a section view showing additional detail of the first axle
channel 808 including opening 812 and second width 814, alignment
tabs 826, and contact pad 818.
In some instances, filament can jump off the spool and into a gap
between the spool and the well. The filament then can get wrapped
around the axle, for example in situations in which slack is
introduced into the filament through inertia of the spool
continuing to feed filament even when feed has been halted,
incorrect filament loading that introduces uneven tension,
unloading and attempted reload, and the like.
Embodiments of the present disclosure provide geometries of the
material container body and the material container cover to reduce
jamming of filament, such as filament being wedged into a gap
between the spool and the container in which the spool is placed
for filament feeding. One embodiment of material container 800
includes material well 806 with well ledge landings 832 that are
positioned so as to make a gap 844 (see FIG. 16) between an outer
radial end of the spool walls 202 and 204 smaller than a diameter
or thickness of the filament, reducing the chances of filament
jumping off the spool and into the gap 844 as the spool rotates to
feed filament. The well edge landings 832 extend inwardly from
opposite inner edges of the material container body 802 at a first
radius from the central longitudinal axis 290 of the material
container 800. In one embodiment, the first radius is substantially
equal to a radius of an inserted spool, such as spool 200. Further,
material container 800 includes an extension well 834 that has a
larger radius than the well ledge landings 832 adjacent to the
filament winding area where filament is wound and where filament
can jump into the gap 844 during rotation of the spool 250. In one
embodiment, the extension well 834 has a width configured to be
substantially the same as a width of the filament winding area 210
of an inserted spool 200. The extension well 834 has a second,
different radius from the central longitudinal axis 290 of the
material container 800 than the first radius of the well edge
landings 832. First radius is shown as radius 848 in FIG. 17, and
second radius is shown as radius 850 in FIG. 17.
When filament becomes slack, the filament moves in a direction of
least resistance. In this embodiment, the direction of least
resistance is into the extension well 834 instead of into the gap
844. This reduces the chances of any snagging of filament in gap
844, and of any jumping of filament from the gap 844 and to the
exterior of the spool 200 where it can wind around axle 250 and jam
the filament feed. This reduction of jamming and snagging increases
filament feed reliability. FIG. 12 illustrates a section view of
material container 800 with material container body 802 and
material container cover 804 taken along section line 12-12 of FIG.
11. Material container cover 804 is rotatably coupled to material
container body 802 via hinges 836, and in one embodiment, is
snapped closed with hinges 838 and a latch (not shown).
FIGS. 13 and 14 illustrate a material container cover 804 according
to one embodiment of the present disclosure. Material container
cover 804 is configured in one embodiment to reduce the chances of
filament jumping out of the filament winding area 210. Material
container cover 804 comprises curved inner guide components 840
that restrict the gap 844 between the edges of spool walls 202 and
204 and the material container cover 804 radially. Curved inner
guide components 840 continue a circumferential barrier to a radius
848 that is slightly larger than a radius of the spool walls 202
and 204, thus assisting in the maintenance of a substantially
uniform gap 844 around an entire rotational arc of the rotating
spool 200. Further, ribs 842 extend laterally inward from the
interior edges 846 of the cover 804 to assist in structural
rigidity of the material container cover, and to assist in aligning
the material container cover 804 with the material container body
802, therefore assisting in the alignment of curved inner guide
components 840 with the radial edges of the spool walls 202 and
204.
FIG. 15 illustrates a partial cutaway view showing a spool 200 on
axle 250 inserted properly into material container body 802 of
material container 800. As can be seen, the end 270 of axle 250 is
in proper position to align its contacts with the contacts of the
material container body 802.
FIG. 16 is a perspective cutaway section view of a portion of the
material container 800 showing the positioning of the spool walls
202 and 204 with respect to the well edge landings 832 and well
extension 834. Gap 844 is reduced and any filament slack will move
into the well extension 834 during spool 200 rotation, and not into
the gap 844, as the path of least resistance.
FIG. 17 is a section view of a material container 800, showing a
spool 200 and axle 250 inserted into material container 800. The
spool 200 rotates about the axle 250. Well edge landings 832 of
material container body 802 combine with curved inner guide
components 840 along an arc 841 thereof to provide a substantially
uniform gap 844 to prevent the jumping of filament on the spool 200
over spool walls 202 or 204 into material container body 802 or
material container cover 804. Arc 841 of curved inner guide
components 840 is positioned at a radius 848 that is the same as
radius 848 between the longitudinal axis 290 and the well edge
landings 832 of material container body 802.
A method of loading three dimensional part material to a 3D printer
comprises aligning a first end of an axle of a spool with a first
tapered axle channel in a material well, and aligning a second end
of the axle with a second tapered axle channel in the material
well. Aligning a first end of an axle further comprises providing
the first tapered axle channel with a top opening sized to
accommodate the first end of the axle in any rotational
orientation, and providing a second portion sized to accommodate
the first end of the axle in a selected orientation, wherein the
selected orientation is configured to align electrical contacts of
the axle with corresponding electrical contacts of the first
tapered axle channel.
A method of reducing snagging of a filament feed spool in a 3D
printer comprises providing a material container having a material
container body with an interior material well and a material
container cover, aligning a plurality of cover ribs with radial
edges of the filament feed spool, aligning well edge landings of
the material well with the radial edges of the filament feed spool,
and providing an extension well in the material well extending
beyond the radial edges of the filament feed spool in a filament
winding area of the filament feed spool.
While two consumable assemblies 12, in one embodiment comprising
spool 200, axle 250, and material container 800, are shown and
discussed herein, it should be understood that more or fewer
consumable assemblies may be used without departing from the scope
of the disclosure.
Although the present disclosure has been described with reference
to preferred embodiments, workers skilled in the art will recognize
that changes may be made in form and detail without departing from
the spirit and scope of the disclosure.
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